Pub Date : 2025-05-01Epub Date: 2024-12-14DOI: 10.1016/j.ijlmm.2024.12.003
Valentino A.M. Cristino , Rui FV. Sampaio , João P.M. Pragana , Ivo M.F. Bragança , Carlos M.A. Silva , Paulo A.F. Martins
This paper is focused on the hybridization of metal additive manufacturing with bending to shape thin-walled deposited materials into fully three-dimensional custom parts with specific angles. The presentation covers material deposition by laser powder bed fusion, material and formability characterization using tension and three-point bending tests, and proof-of-concept validation through bending a flat, cross-shaped, deposited plate into a slender three-dimensional double U-shaped part. The use of digital image correlation and finite element analysis supports the presentation as well as the design and creation of the part. Results underscore the significance of hybridizing metal additive manufacturing with bending due to the gains obtained in material usage and fabrication time of 87.9 % and 85.7 %, respectively. The overall methodology integrating material deposition, formability analysis, and combined experimental and finite element simulation of bending proves effective for designing hybrid metal additive-manufactured parts, providing a comprehensive framework for future research and development in this area.
{"title":"Enhancing the performance of laser powder bed fusion through hybridization with bending","authors":"Valentino A.M. Cristino , Rui FV. Sampaio , João P.M. Pragana , Ivo M.F. Bragança , Carlos M.A. Silva , Paulo A.F. Martins","doi":"10.1016/j.ijlmm.2024.12.003","DOIUrl":"10.1016/j.ijlmm.2024.12.003","url":null,"abstract":"<div><div>This paper is focused on the hybridization of metal additive manufacturing with bending to shape thin-walled deposited materials into fully three-dimensional custom parts with specific angles. The presentation covers material deposition by laser powder bed fusion, material and formability characterization using tension and three-point bending tests, and proof-of-concept validation through bending a flat, cross-shaped, deposited plate into a slender three-dimensional double U-shaped part. The use of digital image correlation and finite element analysis supports the presentation as well as the design and creation of the part. Results underscore the significance of hybridizing metal additive manufacturing with bending due to the gains obtained in material usage and fabrication time of 87.9 % and 85.7 %, respectively. The overall methodology integrating material deposition, formability analysis, and combined experimental and finite element simulation of bending proves effective for designing hybrid metal additive-manufactured parts, providing a comprehensive framework for future research and development in this area.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 301-309"},"PeriodicalIF":0.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791536","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-05-01Epub Date: 2025-02-06DOI: 10.1016/j.ijlmm.2025.02.004
Xinlong Zhang, Jiang Xiao, Xiaodong Xie, Zhaosong Jiang, Xueyan Liu
A study was conducted to examine the distribution of wall thickness in stainless steel thin-walled tube fittings during the forming process. The research included simulation and experimental analyses of the bending and hydroforming processes of these fittings used in a passenger car. The goal was to analyze how process parameters affect the distribution of wall thickness. Auto Form software was utilized to simulate the bending process and investigate the impact of relative bending radius (Relative bending radius for the tube fittings bending neutral layer of the ratio of the radius and diameter of the tube) on the wall thickness distribution. Subsequently, hydroforming simulations were performed under varying internal pressure loading conditions. The findings revealed that as the relative bending radius increased, both the maximum thinning rate and maximum thickening rate of the tube fittings gradually decreased. Based on the simulation outcomes, the optimal bending process parameters were determined to be a 62 mm initial tube diameter and a 95 mm bending radius. Through finite element simulations of hydroforming, internal pressures of 30 MPa, 40 MPa, and 50 MPa were compared, with 40 MPa identified as the optimal pressure for forming. The thin-walled tube fittings were then manufactured based on the optimal parameters obtained from the simulation, which were validated through experimentation. The experimental results closely matched the simulation results, with a maximum error margin of 2.27 %. The final formed parts met all requirements without any failures.
{"title":"Bending-hydraulic forming stainless steel thin-walled tube fittings wall thickness distribution law research","authors":"Xinlong Zhang, Jiang Xiao, Xiaodong Xie, Zhaosong Jiang, Xueyan Liu","doi":"10.1016/j.ijlmm.2025.02.004","DOIUrl":"10.1016/j.ijlmm.2025.02.004","url":null,"abstract":"<div><div>A study was conducted to examine the distribution of wall thickness in stainless steel thin-walled tube fittings during the forming process. The research included simulation and experimental analyses of the bending and hydroforming processes of these fittings used in a passenger car. The goal was to analyze how process parameters affect the distribution of wall thickness. Auto Form software was utilized to simulate the bending process and investigate the impact of relative bending radius (Relative bending radius for the tube fittings bending neutral layer of the ratio of the radius and diameter of the tube) on the wall thickness distribution. Subsequently, hydroforming simulations were performed under varying internal pressure loading conditions. The findings revealed that as the relative bending radius increased, both the maximum thinning rate and maximum thickening rate of the tube fittings gradually decreased. Based on the simulation outcomes, the optimal bending process parameters were determined to be a 62 mm initial tube diameter and a 95 mm bending radius. Through finite element simulations of hydroforming, internal pressures of 30 MPa, 40 MPa, and 50 MPa were compared, with 40 MPa identified as the optimal pressure for forming. The thin-walled tube fittings were then manufactured based on the optimal parameters obtained from the simulation, which were validated through experimentation. The experimental results closely matched the simulation results, with a maximum error margin of 2.27 %. The final formed parts met all requirements without any failures.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 402-414"},"PeriodicalIF":0.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800352","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-05-01Epub Date: 2025-01-06DOI: 10.1016/j.ijlmm.2025.01.001
Ferhat Kadioglu
Thermoplastic composites as emerging materials for aerospace and automotive industries are suitable for mass-production and recycling. Healing is one of their inherent features when being damaged. This study aims to focus on the fusion bonding of a thermoplastic composite reinforced with carbon fibers. The material was fabricated in the Single Lap Joints (SLJs) configuration using a co-cured manufacturing method. First, the joints were subjected to quasi-static tensile tests to failure. The pristine joints with a 20 mm overlap length gave an average maximum load of about 5.5 kN. Then, the damaged joints were healed and subjected to the same test conditions to see their performance. It was observed that the thermoplastic adherends were able to be healed almost fully, giving a joint strength of about 5.2 kN, implying about 5 % of a decrement. Numerical works were also undertaken to see stress distributions in the joint and to predict the joint failure. Further investigations have shown the lap shear performance of such joints could be improved through different designs with no additional weight in the joint, which is feasible using the co-cured manufacturing methods.
{"title":"Improving healing capability of the thermoplastic composites reinforced with carbon fibres in a Single Lap Joint (SLJ) using a co-cured method","authors":"Ferhat Kadioglu","doi":"10.1016/j.ijlmm.2025.01.001","DOIUrl":"10.1016/j.ijlmm.2025.01.001","url":null,"abstract":"<div><div>Thermoplastic composites as emerging materials for aerospace and automotive industries are suitable for mass-production and recycling. Healing is one of their inherent features when being damaged. This study aims to focus on the fusion bonding of a thermoplastic composite reinforced with carbon fibers. The material was fabricated in the Single Lap Joints (SLJs) configuration using a co-cured manufacturing method. First, the joints were subjected to quasi-static tensile tests to failure. The pristine joints with a 20 mm overlap length gave an average maximum load of about 5.5 kN. Then, the damaged joints were healed and subjected to the same test conditions to see their performance. It was observed that the thermoplastic adherends were able to be healed almost fully, giving a joint strength of about 5.2 kN, implying about 5 % of a decrement. Numerical works were also undertaken to see stress distributions in the joint and to predict the joint failure. Further investigations have shown the lap shear performance of such joints could be improved through different designs with no additional weight in the joint, which is feasible using the co-cured manufacturing methods.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 385-392"},"PeriodicalIF":0.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800357","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-05-01Epub Date: 2024-12-16DOI: 10.1016/j.ijlmm.2024.12.002
Wael A. Altabey
Failure detection-based Electrical Potential Change (EPC) is a promising technique. In this article, the internal layers delamination is inspected in basalt fiber-reinforced polymer (BFRP) pipe under long-term fatigue loading (LTFL) of internal pressure effect via an Electrical Capacitance Sensor (ECS) by evaluating the dielectric characteristics of pipe materials and classification between intact and delamination stats. The 3D maps of the capacitance array values and EPC distribution of node potential are tested. The maps can reflect delamination between pipe layers based on the researcher's previous works, however, because the pipes are modeled in 3D, therefore, the bending and twisted effects of the model make these maps not a good choice to accurately detect delamination location/size. Therefore, a new type of convolutional neural network (CNN) algorithm is adopted to train and test the EPC maps to evaluate delamination location/size. The training accuracy of the current technology (), recall rate (), and F-score () are equal to , , and respectively, which indicates that the current technology shows identification efficiency and accuracy of the technology. The proposed method results converge with available traditional methods in the literature for assessing the delamination location/size such as the response surface methodology (RSM), and the error band from the diagonal line is less than and degrees for location and size respectively, thus validating the proposed technique's reliability, accuracy, and applicability for the relevant structures.
{"title":"A novel framework to identify delamination location/size in BFRP pipe based on convolutional neural network (CNN) algorithm hybrid with capacitive sensors","authors":"Wael A. Altabey","doi":"10.1016/j.ijlmm.2024.12.002","DOIUrl":"10.1016/j.ijlmm.2024.12.002","url":null,"abstract":"<div><div>Failure detection-based Electrical Potential Change (EPC) is a promising technique. In this article, the internal layers delamination is inspected in basalt fiber-reinforced polymer (BFRP) pipe under long-term fatigue loading (LTFL) of internal pressure effect via an Electrical Capacitance Sensor (ECS) by evaluating the dielectric characteristics of pipe materials and classification between intact and delamination stats. The 3D maps of the capacitance array values and EPC distribution of node potential are tested. The maps can reflect delamination between pipe layers based on the researcher's previous works, however, because the pipes are modeled in 3D, therefore, the bending and twisted effects of the model make these maps not a good choice to accurately detect delamination location/size. Therefore, a new type of convolutional neural network (CNN) algorithm is adopted to train and test the EPC maps to evaluate delamination location/size. The training accuracy of the current technology (<span><math><mrow><mi>P</mi><mo>%</mo></mrow></math></span>), recall rate (<span><math><mrow><mi>R</mi><mo>%</mo></mrow></math></span>), and F-score (<span><math><mrow><mi>F</mi><mo>%</mo></mrow></math></span>) are equal to <span><math><mrow><mn>95.2</mn><mo>%</mo></mrow></math></span>, <span><math><mrow><mn>93.7</mn><mo>%</mo></mrow></math></span>, and <span><math><mrow><mn>90.9</mn><mo>%</mo></mrow></math></span> respectively, which indicates that the current technology shows identification efficiency and accuracy of the technology. The proposed method results converge with available traditional methods in the literature for assessing the delamination location/size such as the response surface methodology (RSM), and the error band from the diagonal line is less than <span><math><mrow><mn>4.86</mn></mrow></math></span> and <span><math><mrow><mn>1.14</mn></mrow></math></span> degrees for location and size respectively, thus validating the proposed technique's reliability, accuracy, and applicability for the relevant structures.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 393-401"},"PeriodicalIF":0.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800354","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-05-01Epub Date: 2025-02-07DOI: 10.1016/j.ijlmm.2025.02.003
Radhika Mandala , B. Anjaneya Prasad , Suresh Akella
The most prevalent and extensively employed additive manufacturing (AM) approach method is fused deposition modeling (FDM), which uses filament as feedstock. Pellet additive manufacturing (PAM) is an emerging technique within the field of FDM that utilizes thermoplastic pellets as the feedstock considering their greater ease of production compared to filaments. The PAM technique enables the production of intricate components with high dimensional precision and cost efficiency by eliminating the need to transform pellets into filaments. The discreet choice of printing parameters greatly influences the performance of 3D-printed objects. This work underscores the significance of printing parameters on mechanical performance measures, tensile, flexure, and hardness characteristics by utilizing a multi-objective optimization technique. It is a combination of the Taguchi, analysis of variance (ANOVA), and entropy-based grey relational analysis (EGRA). A Taguchi L9 orthogonal array is employed, with infill pattern, raster angle, and layer height as the control variables, while tensile and flexural strengths, and hardness serve as the output responses. The findings demonstrated that the optimum outcomes were achieved for the gyroid infill pattern at 45° orientation and 0.25 mm layer height. Enforcing EGRA in multi-objective optimization has resulted in an improvement of 3.3 % in the grey relational grade when compared to the initial parameter configurations. Hence, EGRA proves to be an effective potential tool for the optimization process in PAM.
{"title":"Enhancing the mechanical properties of 3D-Printed polylactic acid through pellet additive manufacturing: A grey relational analysis based on entropy weights","authors":"Radhika Mandala , B. Anjaneya Prasad , Suresh Akella","doi":"10.1016/j.ijlmm.2025.02.003","DOIUrl":"10.1016/j.ijlmm.2025.02.003","url":null,"abstract":"<div><div>The most prevalent and extensively employed additive manufacturing (AM) approach method is fused deposition modeling (FDM), which uses filament as feedstock. Pellet additive manufacturing (PAM) is an emerging technique within the field of FDM that utilizes thermoplastic pellets as the feedstock considering their greater ease of production compared to filaments. The PAM technique enables the production of intricate components with high dimensional precision and cost efficiency by eliminating the need to transform pellets into filaments. The discreet choice of printing parameters greatly influences the performance of 3D-printed objects. This work underscores the significance of printing parameters on mechanical performance measures, tensile, flexure, and hardness characteristics by utilizing a multi-objective optimization technique. It is a combination of the Taguchi, analysis of variance (ANOVA), and entropy-based grey relational analysis (EGRA). A Taguchi L9 orthogonal array is employed, with infill pattern, raster angle, and layer height as the control variables, while tensile and flexural strengths, and hardness serve as the output responses. The findings demonstrated that the optimum outcomes were achieved for the gyroid infill pattern at 45° orientation and 0.25 mm layer height. Enforcing EGRA in multi-objective optimization has resulted in an improvement of 3.3 % in the grey relational grade when compared to the initial parameter configurations. Hence, EGRA proves to be an effective potential tool for the optimization process in PAM.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 331-340"},"PeriodicalIF":0.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791543","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-05-01Epub Date: 2025-02-04DOI: 10.1016/j.ijlmm.2025.02.001
Equbal Ahmed , Muhammed Muaz , Sajjad Arif , Ravi Kant , Syed Mohd Hamza , Md Kashif Alim , Musab Ahmad Khan , Jaber Abu Qudeiri , Sanan H. Khan
Friction Stir Welding (FSW) is a solid-state joining technique that has garnered significant attention for its ability to weld aluminum alloys while mitigating common issues such as porosity and thermal defects inherent in fusion welding. This study systematically evaluates the impact of inter-layers and powder additives on the mechanical properties of aluminum FSW joints. Magnesium (Mg) ribbons and Lead–Tin (Sn–Pb) alloy ribbons were employed as inter-layers, while Boron Carbide (B4C), Titanium Dioxide (TiO2), and Manganese (Mn) served as reinforcement powders. Quantitative analysis demonstrated that the combination of Manganese (Mn) powder and Sn–Pb alloy inter-layer achieved a remarkable 28 % improvement in hardness, a 35 % reduction in wear rate, and a 42 % increase in shear strength. Additionally, Mn powder alone yielded the highest shear strength, while Sn–Pb inter-layer with Mn powder provided maximum hardness and wear resistance. Mg ribbon combined with Mn powder produced the lowest surface roughness. These enhancements were corroborated by mechanical testing and morphological characterization, including scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and microstructural mapping. The findings highlight the effectiveness of tailored inter-layer and powder combinations in enhancing weld quality, providing insights into the underlying mechanisms responsible for these improvements. This study underscores the industrial relevance of these advancements, offering transformative potential for sectors such as aerospace and automotive manufacturing where superior joint properties are critical.
{"title":"Lightweight aluminum joint design: Enhancement of mechanical properties through novel inter-layer and powder additives in friction stir welding","authors":"Equbal Ahmed , Muhammed Muaz , Sajjad Arif , Ravi Kant , Syed Mohd Hamza , Md Kashif Alim , Musab Ahmad Khan , Jaber Abu Qudeiri , Sanan H. Khan","doi":"10.1016/j.ijlmm.2025.02.001","DOIUrl":"10.1016/j.ijlmm.2025.02.001","url":null,"abstract":"<div><div>Friction Stir Welding (FSW) is a solid-state joining technique that has garnered significant attention for its ability to weld aluminum alloys while mitigating common issues such as porosity and thermal defects inherent in fusion welding. This study systematically evaluates the impact of inter-layers and powder additives on the mechanical properties of aluminum FSW joints. Magnesium (Mg) ribbons and Lead–Tin (Sn–Pb) alloy ribbons were employed as inter-layers, while Boron Carbide (B<sub>4</sub>C), Titanium Dioxide (TiO<sub>2</sub>), and Manganese (Mn) served as reinforcement powders. Quantitative analysis demonstrated that the combination of Manganese (Mn) powder and Sn–Pb alloy inter-layer achieved a remarkable 28 % improvement in hardness, a 35 % reduction in wear rate, and a 42 % increase in shear strength. Additionally, Mn powder alone yielded the highest shear strength, while Sn–Pb inter-layer with Mn powder provided maximum hardness and wear resistance. Mg ribbon combined with Mn powder produced the lowest surface roughness. These enhancements were corroborated by mechanical testing and morphological characterization, including scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and microstructural mapping. The findings highlight the effectiveness of tailored inter-layer and powder combinations in enhancing weld quality, providing insights into the underlying mechanisms responsible for these improvements. This study underscores the industrial relevance of these advancements, offering transformative potential for sectors such as aerospace and automotive manufacturing where superior joint properties are critical.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 341-354"},"PeriodicalIF":0.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791544","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-05-01Epub Date: 2024-12-26DOI: 10.1016/j.ijlmm.2024.12.004
ZeWen Li , Hao Chen , Zheng Liu
The effects of different stirring methods on the melt flow field and solidification structure of the alloy were studied by numerical simulation under the same stirring parameters. The results of numerical simulation and experimental study show that two-way continuous electromagnetic stirring (forward turning 6s, reverse turning 6s) is better than one-way continuous electromagnetic stirring (forward turning 12s) and two-way intermittent electromagnetic stirring (forward turning 6s, stop 1s, reverse turning 6s). A new process and process parameters for preparing semi-solid aluminum alloy slurry were formed and improved. When aluminum alloy melt was poured into the cast at 650 °C, the maximum melt flow rate was obtained under 4 A, 30 Hz, and bidirectional continuous electromagnetic stirring for 12s (forward rotation 6s, reverse 6s). At this time, the maximum X-axis flow rate of aluminum alloy melt was 82 mm/s. The maximum flow rate on the Y-axis is 72.5 mm/s, and the maximum flow rate on the Z-axis is 45.6 mm/s. At this time, the microstructure of the primary phase is the best, the average equal area circle diameter of the primary phase is 59.3 μm, and the average shape factor is 0.84.
{"title":"Effect of electromagnetic stirring method on flow characteristics of A356 aluminum alloy melt","authors":"ZeWen Li , Hao Chen , Zheng Liu","doi":"10.1016/j.ijlmm.2024.12.004","DOIUrl":"10.1016/j.ijlmm.2024.12.004","url":null,"abstract":"<div><div>The effects of different stirring methods on the melt flow field and solidification structure of the alloy were studied by numerical simulation under the same stirring parameters. The results of numerical simulation and experimental study show that two-way continuous electromagnetic stirring (forward turning 6s, reverse turning 6s) is better than one-way continuous electromagnetic stirring (forward turning 12s) and two-way intermittent electromagnetic stirring (forward turning 6s, stop 1s, reverse turning 6s). A new process and process parameters for preparing semi-solid aluminum alloy slurry were formed and improved. When aluminum alloy melt was poured into the cast at 650 °C, the maximum melt flow rate was obtained under 4 A, 30 Hz, and bidirectional continuous electromagnetic stirring for 12s (forward rotation 6s, reverse 6s). At this time, the maximum X-axis flow rate of aluminum alloy melt was 82 mm/s. The maximum flow rate on the Y-axis is 72.5 mm/s, and the maximum flow rate on the Z-axis is 45.6 mm/s. At this time, the microstructure of the primary phase is the best, the average equal area circle diameter of the primary phase is 59.3 μm, and the average shape factor is 0.84.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 321-330"},"PeriodicalIF":0.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143791538","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
AZ31 Mg alloy is an emerging material that has received considerable attention in aerospace, automotive, and temporary biodegradable implant applications owing to its attractive properties, such as low density, high specific strength, and biodegradability. Nevertheless, some shortcomings in Mg alloys are their low ductility, which is associated with challenging its manufacturing, and poor corrosion resistance associated with unreliable components. Therefore, a cold metal transfer wire arc additive manufacturing (CMT-WAAM) process is used to manufacture AZ31 Mg alloy and achieved 29.4 % ductility by controlling the gas porosity, keyhole porosity, and internal cracks. Further, severe plastic deformation is induced on the surface of deposited parts by low plasticity burnishing (LPB) with parallel and cross-pattern burnishing to modulate their surface to slow down the kinetics of the corrosion damage. The average surface roughness (Sa) of the cross-burnishing pattern is 0.235 μm, which is 123.6 % lower than the parallel burnished and 261.7 % lower than the milled specimens. The residual stress (RS) of WAAM is 40 MPa with a tensile nature; however, it is drastically reduced and develops compressive RS of 45 MPa under a parallel burnishing pattern and 62 MPa under a cross-burnishing pattern. Moreover, LPB with cross pattern deformed ∼395 μm depth of WAAMed AZ31 workpiece, which is ∼45 % higher than deformed depth (∼272 μm) by parallel pattern burnishing. The electrochemical corrosion rate of the WAAM specimen is 9.71 mm/year, and it is reduced to 1.82 mm/year under LPB caused by compressive residual stress and grain refinement.
{"title":"Effect of burnishing strategies on surface integrity, microstructure and corrosion performance of wire arc additively manufactured AZ31 Mg alloy","authors":"Shambhu Kumar Manjhi , Oyyaravelu R , Srikanth Bontha , A.S.S. Balan","doi":"10.1016/j.ijlmm.2024.12.001","DOIUrl":"10.1016/j.ijlmm.2024.12.001","url":null,"abstract":"<div><div>AZ31 Mg alloy is an emerging material that has received considerable attention in aerospace, automotive, and temporary biodegradable implant applications owing to its attractive properties, such as low density, high specific strength, and biodegradability. Nevertheless, some shortcomings in Mg alloys are their low ductility, which is associated with challenging its manufacturing, and poor corrosion resistance associated with unreliable components. Therefore, a cold metal transfer wire arc additive manufacturing (CMT-WAAM) process is used to manufacture AZ31 Mg alloy and achieved 29.4 % ductility by controlling the gas porosity, keyhole porosity, and internal cracks. Further, severe plastic deformation is induced on the surface of deposited parts by low plasticity burnishing (LPB) with parallel and cross-pattern burnishing to modulate their surface to slow down the kinetics of the corrosion damage. The average surface roughness (S<sub>a</sub>) of the cross-burnishing pattern is 0.235 μm, which is 123.6 % lower than the parallel burnished and 261.7 % lower than the milled specimens. The residual stress (RS) of WAAM is 40 MPa with a tensile nature; however, it is drastically reduced and develops compressive RS of 45 MPa under a parallel burnishing pattern and 62 MPa under a cross-burnishing pattern. Moreover, LPB with cross pattern deformed ∼395 μm depth of WAAMed AZ31 workpiece, which is ∼45 % higher than deformed depth (∼272 μm) by parallel pattern burnishing. The electrochemical corrosion rate of the WAAM specimen is 9.71 mm/year<sup>,</sup> and it is reduced to 1.82 mm/year under LPB caused by compressive residual stress and grain refinement.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 3","pages":"Pages 355-373"},"PeriodicalIF":0.0,"publicationDate":"2025-05-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800355","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-05-01Epub Date: 2025-02-10DOI: 10.1016/j.ijlmm.2025.02.002
A. Viswanath , M. Khalil , M.K.A. Khan , W.J. Cantwell , K.A. Khan
Buckling is a common failure mode in low-density strut lattices, limiting their mechanical strength and stability. This work presents a novel methodology to design and manufacture lightweight, buckling-resistant strut-based lattice structures by reinforcing buckling-prone members with hierarchical lattice unit cells—either stretching- or bending-dominated—without changing the strut lattice's relative density. Four types of lattice unit cells were examined: plate, honeycomb, strut, and TPMS solids and sheets. These were tested on single-cell cubic lattice columns with square cross-sectional struts. The resulting hierarchical structures were additively manufactured and experimentally evaluated, demonstrating significantly enhanced buckling performance. Design for additive manufacturing principles were applied, and structures with stretching and bending-dominated unit cells achieved higher critical buckling loads, with the square honeycomb cell lattice showing the highest improvement at 179 % over the baseline. This approach broadens opportunities for enhancing low-density strut lattices and developing novel buckling-resistant designs.
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Pub Date : 2025-03-01Epub Date: 2024-10-09DOI: 10.1016/j.ijlmm.2024.09.004
Piyush Patel, Piyush Gohil
According to patient needs, unique Prosthetic and Orthotic (P&O) elements are created using Additive Manufacturing (AM) without the need for part-dependent equipment. This paper presents the basic information about the element's materials, and techniques of P&O. This paper discusses the detailed procedure for designing, analyzing, and developing various P&O models. Through analysis, the result shows that the desirable values of natural frequency (3103.1 Hz), total deformation (0.00261 mm), and strain energy (0.07011 mJ) of the prosthetic foot model 1 is for carbon fiber material. Therefore, for the preparation of the foot, this material can be selected for the best performance of the prosthetic foot.
Traditionally, individual P&O devices are manufactured using plaster molds, which require multiple patient visits and take a lot of effort and time to produce. Therefore, our main attention is the process of designing and developing lightweight P&O elements quickly with a simplification of the manufacturing process. The AFO and flex foot prosthetic parts are printed using PLA material on FDM machines. The entire process takes less than 7 h, with an average hands-on time of only 10–15 min for AFO parts and about 10 h for Flex-Foot prostheses. In other words, using 3D printing to create a P&O device for a patient is significantly less time-consuming than traditional methods. In the future, it is intended to compare altered effects obtained by using various types of materials for the improvement of the P&O devices by the AM method.
{"title":"Design, analysis and development of prosthetic and orthotic elements by additive manufacturing process","authors":"Piyush Patel, Piyush Gohil","doi":"10.1016/j.ijlmm.2024.09.004","DOIUrl":"10.1016/j.ijlmm.2024.09.004","url":null,"abstract":"<div><div>According to patient needs, unique Prosthetic and Orthotic (P&O) elements are created using Additive Manufacturing (AM) without the need for part-dependent equipment. This paper presents the basic information about the element's materials, and techniques of P&O. This paper discusses the detailed procedure for designing, analyzing, and developing various P&O models. Through analysis, the result shows that the desirable values of natural frequency (3103.1 Hz), total deformation (0.00261 mm), and strain energy (0.07011 mJ) of the prosthetic foot model 1 is for carbon fiber material. Therefore, for the preparation of the foot, this material can be selected for the best performance of the prosthetic foot.</div><div>Traditionally, individual P&O devices are manufactured using plaster molds, which require multiple patient visits and take a lot of effort and time to produce. Therefore, our main attention is the process of designing and developing lightweight P&O elements quickly with a simplification of the manufacturing process. The AFO and flex foot prosthetic parts are printed using PLA material on FDM machines. The entire process takes less than 7 h, with an average hands-on time of only 10–15 min for AFO parts and about 10 h for Flex-Foot prostheses. In other words, using 3D printing to create a P&O device for a patient is significantly less time-consuming than traditional methods. In the future, it is intended to compare altered effects obtained by using various types of materials for the improvement of the P&O devices by the AM method.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 2","pages":"Pages 205-227"},"PeriodicalIF":0.0,"publicationDate":"2025-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143429568","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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